Wear resistant coating, article, and method

ABSTRACT

A wear coating is disclosed that includes a layer treated by a trifunctional organosilane. An article is also disclosed, the article having a surface to which the wear coating is applied. A method of applying the wear coating is also disclosed. In some embodiments, the organosilane is trimethylsilane and the wear coating is applied by chemical vapor deposition, followed by heat treating the wear coating in the presence of the trimethylsilane.

PRIORITY

This application claims priority to and the benefit of U.S. Appl. No.61/389,777, filed Oct. 5, 2010 and U.S. Appl. No. 61/507,650 filed Jul.14, 2011, both of which are hereby incorporated by reference in theirentirety.

FIELD

The present disclosure is directed to a coating. More particularly, thedisclosure is directed to a wear resistant coating applied to asubstrate via decomposition of dimethylsilane.

BACKGROUND

Often, surfaces of substrates do not include desired performancecharacteristics. The failure to include specific desired performancecharacteristics can result in surface degradation in certainenvironments, an inability to meet certain performance requirements, orcombinations thereof For example, in certain environments, metallic,glass, and ceramic surfaces can be subjected to wear and otherundesirable surface activities such as chemical adsorption, catalyticactivity, corrosive attack, oxidation, byproduct accumulation orstiction, and/or other undesirable surface activities.

Undesirable surface activities can cause chemisorption of othermolecules, reversible and irreversible physisorption of other molecules,catalytic reactivity with other molecules, attack from foreign species,a molecular breakdown of the surface, physical loss of substrate orcombinations thereof.

To provide certain desired performance characteristics, a siliconhydride surface and unsaturated hydrocarbon reagents can be reacted inthe presence of a metal catalyst. Such processes suffer from thedrawbacks that complete removal of this catalyst from the treated systemis often difficult and the presence of the catalyst can reintroduceundesirable surface activity. Amorphous silicon-based chemical vapordeposition materials are also susceptible to dissolution by caustic highpH media, thereby limiting their use in such environments.

A coating may be applied to a surface to protect it from undesirablesurface activities. One known method of depositing a coating on asurface is chemical vapor deposition (also commonly referred to as CVD).Generally, chemical vapor deposition deposits a solid material from avapor under controlled atmospheric and temperature conditions for apredetermined time to form a coating. Chemical vapor deposition caninclude a primary treatment followed by functionalization (a surfacereaction) to add predetermined molecules.

However, despite the prior use of chemical vapor deposition generally,molecules including silicon, carbon, and hydrogen have previously beenconsidered undesirable for use as chemical vapor deposition precursorsor have been applied in conjunction with other chemical vapor depositionprecursors in the presence of additional depositional energies such asplasma and microwave fields. Thus, properties associated with suchmolecules have previously been unrealized through thermal chemical vapordeposition technology.

Furthermore, many known coatings do not provide adequate wear resistancewhich can lead to surface wear, which affects the operational life ofthe component on which the coating is applied. As operationalenvironments are normally complex, it is desirable that coatings beformulated to prevent both the chemical and physical degradation to thesurface of the component. An example of a component working in anaggressive environment is a drilling tool used in the oil and gasindustry. The tool experiences high loads, high speeds and friction and,as a consequence high temperatures. Another example is components thatare exposed to reciprocating wear between two surfaces. These factorscan lead to surface wear of the components.

Accordingly, it would be desirable to improve current wear coatings thatcan overcome some or all of these and other drawbacks associated withknown systems.

SUMMARY

An exemplary embodiment of the present disclosure relates to a wearcoating comprising a layer treated by trimethylsilane.

Another exemplary embodiment of the present disclosure relates to anarticle having a surface that comprises a layer treated bytrimethylsilane.

Another exemplary embodiment of the present disclosure relates to amethod of applying a wear coating to an article followed by treatingwith a trifunctional organosilane.

In some embodiments, the wear coating is deposited by a chemical vapordeposition method.

In some embodiments, the trifunctional organosilane is trimethylsilane.

In some embodiments, the wear coating is oxidized and/or functionalizedin addition to being treated with trifunctional organosilane.

An advantage of an embodiment of the present invention is thatpreviously unavailable molecules including silicon, carbon, and hydrogencan be applied to substrate surfaces.

Another advantage of an embodiment of the present invention is thattreatment of a substrate with trimethylsilane or other trifunctionalorganosilane over which substrate a dimethylsilane coating has beenapplied by CVD may provide improvements over untreated oxidized and/orfunctionalized versions of such coatings in one or more of inertness,corrosion resistance, hydrophobicity, pH resistance, wear resistance andhardness.

Another advantage is that the treatment can be used such that thecoating can be adjusted for anti-stiction and anti-coking properties.

Another advantage of an embodiment of the present invention is that wearcoatings having improved wear resistance can be achieved.

Further aspects of embodiments of the invention are disclosed herein.The features as discussed above, as well as other features andadvantages of the present application will be appreciated and understoodby those skilled in the art from the following drawings and detaileddescription.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an exemplary embodiment of a carbosilane coating on asubstrate according to the disclosure.

FIG. 2 shows an Auger Electron Spectroscopy plot for an exemplaryembodiment of a carbosilane coating having a layer on a substrateaccording to the disclosure.

FIG. 3 shows an exemplary embodiment of a functionalized carbosilanecoating on a substrate according to the disclosure.

FIG. 4 shows a chemical vapor deposition method according to anexemplary embodiment of the disclosure.

FIG. 5 shows an exemplary treatment method in a chemical vapordeposition method according to the disclosure.

FIG. 6 shows an exemplary thermal decomposition in a chemical vapordeposition method according to the disclosure.

FIG. 7 shows an exemplary functionalization step in a chemical vapordeposition method according to the disclosure.

FIG. 8 shows an exemplary water oxidation process in a chemical vapordeposition method according to an embodiment of the disclosure.

FIG. 9 shows an exemplary water oxidation process in a chemical vapordeposition and functionalization method according to an embodiment ofthe disclosure.

FIG. 10 shows a FT-IR plot for a dimethylsilane deposited,functionalized surface and a dimethylsilane deposited, functionalizedand water oxidized surface.

FIG. 11 shows an Auger Electron Spectroscopy plot for an exemplaryembodiment of a coating having a water oxidized layer on a substrateaccording to the disclosure.

FIG. 12 shows a chemical vapor deposition method according to anexemplary embodiment of the disclosure.

FIG. 13 shows a process of treating an air oxidized material accordingto an exemplary embodiment of the disclosure.

FIG. 14 shows an Auger Electron Spectroscopy plot for an exemplaryembodiment of a coating on a substrate according to the disclosure.

FIGS. 15-19 show various analytical results for the treated materialillustrated in FIG. 12.

FIG. 20 shows a piston having a wear surface on which a coating isapplied, illustrating applications in which the wear surface is movedover another surface.

FIG. 21 shows a pipe having a wear surface on which a coating isapplied, illustrating application is which the wear surface is exposedto fluid motion.

Wherever possible, the same reference numbers will be used throughoutthe drawings to represent the same parts.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Provided is a coating, coated article, and a method of coating that donot suffer from drawbacks of the prior art. For example, embodiments ofthe coating, article, and method can utilize molecules includingsilicon, carbon, and hydrogen. In one embodiment, the method can beemployed without an additional metal catalyst, devoid of additionalresidual catalyst activity, and combinations thereof. In one embodiment,the method increases hardness without substantially reducing inertness,chemical corrosive resistance, and/or other desirable properties.Exemplary coatings formed according to the disclosure can modifyfunctionality, inertness, tailorability, hydrophobicity, anti-corrosiveand/or anti-stiction behavior, hardness, wear resistance, orcombinations thereof.

The coating is primarily intended to be carried out by chemical vapordeposition, typically but not necessarily by thermal application and notplasma assisted methods. It will further be appreciated that methods ofapplication other than CVD that do not exceed 600° C. may also beemployed.

According to a further embodiment, the coating may be treated bytrimethylsilane. In one embodiment, the coating may be oxidized andthereafter treated by trimethylsilane. Treatment with thetrimethylsilane may provide improvements over untreated oxidized and/orfunctionalized coatings in inertness, corrosion resistance,hydrophobicity, pH resistance, wear resistance and hardness, andcombinations thereof Additionally or alternatively, the coating can beadjusted for anti-stiction and anti-coking properties.

Despite having a lower cost and higher availability than dimethylsilane,trimethylsilane has heretofore been believed to be undesirable forchemical vapor deposition. Generally, it has been believed that the useof trimethylsilane would result in undesirable properties includinghigher decomposition temperatures that may adversely affect themetallurgy of a target substrate and that it would involve prolongeddeposition times, thereby affecting the throughput productioncapability.

Referring to FIG. 1, a substrate 100 according to an exemplaryembodiment can include a surface 105 having improved surface propertiesachieved by controllably depositing a layer 102 that imparts a desiredsurface effect to the substrate 100, a coating 101, an article 103, orcombinations thereof. The coating 101 is formed by chemical vapordeposition (for example, of dimethylsilane to form a carbosilane)followed by oxidation (for example, air-oxidation to form acarboxysilane) and/or functionalization (for example, with a hydrosilaneto form a functionalized carboxysilane).

The imparting of the desired surface effect can improve performance ofthe surface 105 by diffusion of the layer 102 and/or the coating 101into the surface 105 of the substrate 100. The layer 102 can be appliedto any suitable substrate. For example, the substrate 100 can be ametallic substrate (ferrous or non-ferrous), a glass substrate, or aceramic substrate.

In an exemplary embodiment, the layer 102 is formed by thermaldecomposition of dimethylsilane. By thermally decomposingdimethylsilane, the layer 102 includes molecules including silicon,carbon, and hydrogen atoms that can be active sites. These moleculeswithin the layer 102 can include a first portion 104 and a secondportion 106. Generally, the first portion 104 and the second portion 106are not spatially resolvable (for example, the first portion 104 and thesecond portion 106 are defined by the molecules deposited on the layer102 and the molecules may be interspersed throughout the layer 102).Furthermore, use of the terms “first” and “second” is not intended toimply any sequentiality, difference in quantity, difference in size, orother distinction between the two portions. To the contrary, the terms“first” and “second” are used for distinguishing molecular compositionof the two portions. For example, in one embodiment, the first portion104 includes silicon and the second portion 106 includes carbon. In oneembodiment, the first portion 104 and the second portion 106 are boundtogether randomly throughout the layer 102.

FIG. 2 illustrates diffusion of the layer 102 and/or the coating 101into the substrate 100 according to an exemplary embodiment. Applyingdimethylsilane to preselected surfaces has resulted in improved chemicalresistance, improved inertness, and improved adhesion over non-diffusioncoatings. FIG. 2 corresponds to the layer 102 having the first portion104 with carbon and the second portion 106 having silicon. Specifically,FIG. 2 shows the composition of the layer 102 within the substrate 100and/or the article 103 by Auger Electron Spectroscopy measurements ofthe layer 102.

In one embodiment, dimethylsilane is thermally decomposed and depositedas amorphous carbosilane for 15 hours. In this embodiment, the layer 102extends to about 130 nanometers and includes a portion of the diffusionregion 108 identifiable based upon an increased concentration of O anddecreased concentration of C and Si (for example, by at least a factorof four). The range of the layer 102 can be between about 0.1micrometers to about 3.0 micrometers. The diffusion region 108 can bebetween about 5 nanometers and 500 nanometers. In one embodiment, thediffusion region 108 is about 20 nanometers. It will be appreciated thatprecise measurement of the diffusion layer via Auger ElectronSpectroscopy can be offset by surface roughness of the substrate andcoating. Therefore, the diffusion region as measured by Auger ElectronSpectroscopy is not an absolute measurement but a representation of thediffusion mechanism according to the process. The composition of layer102 is about 1:0.95:0.12 ratio of C:Si:O. In contrast, the compositionof dimethylsilane introduced into the chemical vapor deposition chamberhas about a 2:1 ratio of C:Si. It is believed that CH_(x) (x=0-3)moieties are retained and Si—C bonds are broken thus indicating thatlayer 102 includes an amorphous array of Si—C bonding. The amorphousarray provides additional benefits such as decreased cracking orflaking, for example, upon tensile or compressive forces acting on thesubstrate 100, and/or increased adhesion. In one embodiment, multiplelayers of the coating 101 or similar coatings are deposited for thickerlayers or for desired properties.

FIG. 3 shows an exemplary embodiment having a functionalized layer 110.The functionalized layer 110 is formed by thermally reacting siliconhydride moieties with unsaturated hydrocarbons (for example, having theformula H₂C═CH—R and/or HC≡C—R) and includes R-groups bonded to all orpart of first portion 104 of the layer 102. R-groups can be formed byany suitable organic reagent having one or more unsaturated hydrocarbongroups. R-groups can be formed by hydrocarbons, substituted hydrocarbons(for example, halogenated), carbonyls, carboxyls, esters, ethers,amines, amides, sulfonic acids, organometallic complexes, and/orepoxides.

FIG. 4 shows an exemplary chemical vapor deposition method 200 forforming the layer 102 that includes preparing the substrate (step 202)and thermally decomposing dimethylsilane (step 204). Preparing thesubstrate (step 202) can be performed by any suitable treatment method.For example, referring to FIG. 5, preparing the substrate (step 202) caninclude isolating a substrate in a chemical vapor deposition chamber(substep 208), preheating the substrate (substep 210), flushing thechamber (substep 212) with an inert gas, and evacuating the chamber(substep 214).

Isolating the substrate (substep 208) is performed in an inertatmosphere within the chamber. The flow of gas and/or maintenance of avacuum in the chamber can provide the controlled atmosphere. A heatsource can control the temperature in the chamber to desorb water andremove remaining contaminants from the substrate surface (substep 210).For example, the surface to be treated can be included within a chemicalvapor deposition chamber with tubing connections to allow gas flow inand out of the chemical vapor deposition chamber. The chamber caninclude multiple controlled inlets and outlets configured for providingand removing multiple gas streams. A vacuum may be connected to one ormore outlet tubes.

Depending upon the cleanliness of the substrate, the substrate may beprepared by heating (substep 210) at a temperature above about 100° C.at a pressure of below about 1 atmosphere for a period ranging from afew minutes to about 15 hours. Generally, the temperature of the heatingcorresponds to the properties of the substrate 100. In one embodiment,the period is from about 0.5 to about 15 hours. In another embodiment,the substrate is heated at about 450° C. for about 2 hours. Afterpreparation under vacuum, the chamber may be selectively flushed(substep 212) with an inert gas and evacuated (substep 214).

Method 200 includes thermally decomposing the dimethylsilane (step 204).In general, dimethylsilane is not readily obtainable due to the lowdemand for it. Dimethylsilane has been regarded as undesirable in somechemical vapor deposition applications because it includes carbon and ismuch more expensive than silane. Silane and the monomethyl analogue todimethylsilane, methylsilane, are both pyrophoric and may explode inair. Dimethylsilane, although flammable, is not pyrophoric. Thus, use ofdimethylsilane can decrease safety risks. In addition, use ofdimethylsilane can result in inertness of a coating and/or chemicalresistance, thereby protecting a surface of a substrate.

Referring to FIG. 6, thermal decomposition of dimethylsilane (step 204)includes introducing dimethylsilane (substep 216) into the chamber at apredetermined pressure and temperature sufficient to decomposedimethylsilane, depositing constituents from decomposition onto thesubstrate 100 (substep 217), coating the substrate (substep 218) for apredetermined period of time to achieve a predetermined thickness,and/or purging the chamber of dimethylsilane (substep 220). As isdescribed in U.S. Pat. No. 6,444,326, which is incorporated herein byreference in its entirety, exemplary process conditions may includepressure being between about 0.01 psia to about 200 psia. Thetemperature can be between about 200° and 600° C. The time period can befrom about 10 minutes to about 24 hours.

In one embodiment, the dimethylsilane introduced (substep 216) includesdimethylsilane in gaseous form. In one embodiment, the substrate isexposed to dimethylsilane gas at a pressure between about 1.0 psia andabout 100 psia and a temperature between about 300° and 600° C. for atime of about 30 minutes to about 24 hours. In an exemplary embodiment,the substrate 100 is exposed to dimethylsilane gas at a temperaturebetween about 400° and about 500° C. for about 15 hours. The pressure ofthe dimethylsilane gas may be between about 5 psia and about 40 psia.

The dimethylsilane is then thermally dissociated into molecularfragments including H, C, Si, and combinations thereof, and theconstituents are deposited onto the substrate 100 (substep 217), therebyforming the coating 100 (substep 218) with a material including silicon,carbon, and hydrogen resulting from decomposition of dimethylsilane.Dimethylsilane gas may be introduced into the reaction chamber underreduced pressure or with an inert gas, such as nitrogen, helium, and/orargon, as a partial pressure dilutant. Although not intending to bebound by theory, it is believed that the dimethylsilane thermallydecomposes to form carbosilyl fragments, which recombine and bind to thesubstrate surface. It is believed that the resultant coating includesamorphous carbosilanes having carbon, silicon, and hydrogen on thesubstrate surface as well as on exposed surfaces of the chamber. Thedeposited material also diffuses into the surface 105 of the substrate100 as is illustrated in the Auger Electron Spectroscopy depth profile(FIG. 2, the diffusion region 108) thus supporting the mode of adhesionto the substrate 100. The chamber may then be purged of dimethylsilaneand volatile, non-deposited carbosilyl fragments (substep 220). If athicker deposition layer is desired, deposition conditions are changed.This is accomplished by changing temperature, pressure, time, orcombinations thereof. Multiple layers can also be applied by repeatingstep 204.

Upon the layer 102 (as further described with reference in FIGS. 1 and2) being formed, additional steps may be performed. In one embodiment,the layer 102 is functionalized next (step 206) as further describedbelow with reference to FIG. 7 to form the functionalized layer 110. Inone embodiment, the layer 102 (for example, amorphous carbosilane) isoxidized (step 205) as further described below with reference to FIG. 8to form an initially-oxidized layer 802 (for example, amorphouscarboxysilane). In one embodiment, the functionalized layer 110 (forexample, functionalized amorphous carbosilane) is oxidized with water toform a functionalized-then-oxidized layer 804 (for example,functionalized amorphous carboxysilane) as further described below withreference to FIG. 9. In one embodiment, the oxidized layer 802 isfunctionalized to form an oxidized-then-functionalized layer (notshown). As used herein, the term “oxidized layer” generally refers toone or more of the initially-oxidized layer 802, thefunctionalized-then-oxidized layer 804, and theoxidized-then-functionalized layer (not shown).

In one embodiment, the method 200 further includes functionalizing thelayer 102 of the substrate 100 (step 206) to form the functionalizedlayer 110, as briefly discussed above with reference to FIG. 3.Referring to FIG. 7, functionalizing the layer 102 of the substrate 100(step 206) may be performed by reacting with silicon hydride moietiesremaining from the original carbosilane deposition (step 204). Followingthe carbosilane deposition on the substrate (step 204), the system ispurged with an inert gas (which can be purging of substep 220 or aseparate purge step) while the reaction chamber can be set to apredetermined functionalization temperature (substep 232). The purgeremoves gaseous carbosilane moieties and/or unreacted dimethlysilanemoieties not bound to the substrate surface. After the purge and settingof the temperature (substep 232), the chamber is evacuated (substep234).

Next, a binding agent is introduced into the chamber at a predeterminedtemperature and pressure within the chamber (substep 236). In oneembodiment, with heat as a driving force, the binding reagent reactswith and binds to the carbosilyl surface via silicon hydride moieties.Binding agent examples are ethylene, propylene, and substitutedunsaturated organic molecules. Residual moieties of the silicon hydridemay be reacted under heat (for example, at about 400° C.) with H₂C═C—Rand/or HC≡C—R. R-groups can be formed by hydrocarbons, substitutedhydrocarbons (for example, halogenated), carbonyls, carboxyls, esters,ethers, amines, amides, sulfonic acids, organometalic complexes, and/orepoxides.

In one embodiment, binding agent molecules are then bound to thesubstrate (substep 240). The coating can include a carbon-siliconcovalent bond with an R-group. The R-group can be modified to adjust theproperties of the surface. For example, the R-group can be modified toadjust the hydrophobicity of the surface. To adjust the hydrophobicityof the surface, the R-group can be a fluorinated hydrocarbon. Thefluorinated hydrocarbon can form a hydrophobic and/or oleophobicsurface. Additionally or alternatively, the R-group can include anorganometallic substituent providing catalytic or biocidal properties.Although not intending to be bound by theory, it is believed that themoieties of silicon hydride can thermally react, via a hydrosilyationmechanism, with unsaturated hydrocarbon groups to covalently bond to thesurface of the coated substrate. The resultant coating on all exposedsurface within the reaction chamber includes covalently-bound R-groupswhich includes the R-group and carbon, silicon, and hydrogen moieties.

In one embodiment, method 200 further includes oxidizing the layer 102of the substrate 100 (step 205) as briefly described above. Layer 102 isoxidized to form the oxidized layer (see above) by exposure to anysuitable chemical species capable of donating a reactive oxygen speciesinto the layer 102 under predetermined oxidation conditions. Forexample, the chemical species may be water, oxygen, air, nitrous oxide,ozone, peroxide, and combinations thereof. In general, oxidation is abulk reaction that affects the bulk of the coating 101. The oxidationmay be controlled by increasing or decreasing the temperature within thechamber, the exposure time within the chamber, the type and/or amount ofdiluent gases, pressure, and/or other suitable process conditions.Control of the oxidation can increase or decrease the amount and/ordepth of oxidation and, thus, the wear resistance and/or hardness of thesurface. In one embodiment, the layer 102 is exposed to water (forexample, in an inert gas at a pressure of about 100 to 200 psia forabout 450° C. for about two hours). In one embodiment, thefunctionalized layer 110 is exposed to water (for example, in an inertgas at a pressure of about 100 to 200 psia for about 450° C. for abouttwo hours).

The oxidation improves hardness and/or wear resistance of carbosilaneand functionalized carbosilane-based chemical vapor deposition processmaterials on ferrous metallic surfaces, non-ferrous metallic surfaces,and/or glass surfaces by controlled oxidation. In one embodiment,referring to FIG. 8, the layer 102 is an amorphous layer of carbosilanethat is oxidized to form an amorphous layer of carboxysilane as theinitially-oxidized layer 802. In one embodiment, referring to FIG. 9,the functionalized layer 110 is an amorphous layer of functionalizedcarbosilane that is oxidized to form an amorphous surface offunctionalized carboxysilane as the functionalized-then-oxidized layer804.

In one embodiment, the oxidizing (step 205) is performed with nitrousoxide (N₂O). Specifically, N₂O is applied under heat (for example, about450° C.) with a pressure of pure N₂O in a vessel with carbosilane-coatedsamples. In this embodiment, the oxidizing (step 205) over-oxidizes andthe over-oxidizing results in having a contact angle of about 60°,increases an amount of N—H, Si—OH, and/or C—OH groups, results in havingrelatively fragile scratch resistance, and increases acidresistance/corrosion resistance.

In one embodiment, the oxidizing (step 205) is performed with ozone. Inthis embodiment, the oxidizing (step 205) decreases wear resistance,decreases chemical resistance, decreases scratch resistance, decreaseshardness, and increases acid resistance/corrosion resistance.

In one embodiment, the oxidizing (step 205) is performed with water(only) as an oxidizing reagent (for example, at a temperature of about450° C.). In this embodiment, the oxidizing (step 205) results in havinga contact angle on a Si wafer of about 86.6°, lowers friction (incomparison to using an oxidizing reagent of air and water), decreaseswear resistance (for example, in comparison to using an oxidizingreagent of air and water), and forms Si—O—Si groups (as illustrated inFIG. 10 by a growth of the Si—O—Si peak at 1026.9 cm⁻¹ compared to thenon-water functionalized peak at 995.2 cm⁻¹).

In another embodiment, the oxidizing (step 205) is performed with anoxidizing reagent including air and water (for example, at a temperatureof about 450° C.). In this embodiment, oxidizing (step 205)over-oxidizes and decreases an amount of C—H groups (for example, incomparison to using water alone as an oxidizing reagent), decreases anamount of Si—C groups (for example, in comparison to using water aloneas an oxidizing reagent), and increases an amount of Si—OH/C—OH groups(for example, in comparison to using water alone as an oxidizingreagent).

In another embodiment, the oxidizing (step 205) is performed with air(only) (for example, at a temperature of about 450° C.). In thisembodiment, oxidizing (step 205) lowers friction (for example, incomparison to using an oxidizing reagent of air and water), increaseswear resistance (for example, in comparison to using an oxidizingreagent of air and water), and forms Si—O—Si groups.

In one embodiment, the layer 102 has a predetermined contact angle (forexample, about 98.3° advancing) and the functionalized layer 110 has ahigher contact angle (for example, about 100° advancing). In oneembodiment, the layer 102 has a predetermined contact angle (forexample, about 95.6° advancing) and a functionalized then oxidized layer804 has a lower contact angle (for example, about 65.9° receding). Inthis embodiment, the oxidizing (step 205) forms Si—O—Si groups anddecreases an amount of Si—H groups (for example, in comparison to thefunctionalized layer 110).

In one embodiment, the oxidized layer has a lower coefficient offriction (for example, about 0.84) than the non-oxidized layer 102 (forexample, about 0.97). Similarly, in one embodiment, the oxidized layerhas a lower wear rate (for example, about 6.75×10⁻⁵ mm³/N/m) than thenon-oxidized layer 102 (for example, 4.73×10⁻⁴ mm³/N/m).

FIG. 11 illustrates diffusion of the oxidized layer into the substrate100 (for example, stainless steel) according to an exemplary embodimentusing water for oxidation. Specifically, FIG. 11 shows the compositionof the oxidized layer within the substrate 100, the coating 101, and thearticle 103 by Auger Electron Spectroscopy. As shown, the oxidation isillustrated by Si—H moieties undergoing oxidation and elimination tocreate Si—O—Si linkages, as well as some Si—C and/or free carbon speciesbeing eliminated. In one embodiment, the oxidized layer extends to about1600 Angstroms and includes the diffusion region 108 being about 250Angstroms, identifiable based upon a decreased concentration of C andSi. The range of the oxidized layer can be between about 0.1 micrometersand about 3.0 micrometers. The diffusion region 108 can be between about5 nanometers and 500 nanometers. The composition of the oxidized layeris about 1.0:1.22:0.91 (C:Si:O) with an increase in oxygen due to thepreexisting oxide layer on substrate 100.

The layer 102 can also be oxidized in the presence of a differentoxidation reagent. In one embodiment, the oxidation reagent is zero air.As used herein, the term “zero air” refers to atmospheric air havingless than about 0.1 ppm total hydrocarbons. In one embodiment, theoxidation reagent consists of gaseous reagents. Due to the gaseousprocessing agents (for example, dimethylsilane and/or nitrogen) being inthe gas phase, use of a gaseous oxidation reagent results in simplerscale-up for manufacturing, a more transferable process, and a moreeconomical process.

Thus, used consistent with embodiments of the disclosure, dimethylsilanehas several benefits for chemical vapor deposition. Additionally, adimethylsilane-deposited material via thermal chemical vapor depositionhas Si—H moieties available for surface functionalization withunsaturated hydrocarbons of formula H₂C═CH—R or HC≡C—R. However, it isalso known that oxidation of the carbosilane material to a carboxysilanematerial provides a dramatic improvement in material hardness andwear-resistance, yet sacrifices desirable qualities such as inertnessand anti-corrosive performance.

Furthermore, although the oxidizing agents herein may be satisfactory inmany instances, in some cases using water as the oxidation reagentpresents various complexities. To achieve pressure andcorrosion-resistance specifications, the size and weight of the chambersnecessary can be very high and pose safety hazards. To safely injectwater into the chamber, substantial cooling is used. For example, for achamber that runs at greater than about 300° C., the system is firstcooled below about 100° C. This can result in a drain on energy and/ortime of manufacturing resources. Also, accurate dispensing of the waterinto the chamber can be complicated and expensive due to the water beinga liquid.

Similarly, using air as the reagent can also present variouscomplexities in some situations. The coated material formed may includethe presence of —OH functionalities that can lead to adsorption inanalytical and chromatographic applications. The material formed canhave low impedance values at low frequency translating to inferioranti-corrosive performance. Also, the material formed can have low watercontact angle values or high hydrophilicity.

While simpler, the use of air as the oxidation reagent can result in aloss of material properties of the coating. For example, in oneembodiment, the coating 101 includes the presence of —OH functionalitiesthat lead to adsorption in analytical and chromatographic applications.In one embodiment, the coating 101 has low impedance values at lowfrequency translating to inferior anti-corrosive performance. In oneembodiment, the coating 101 has low contact angle values or highhydrophilicity.

Although these properties seem to render use of air as the oxidationreagent undesirable, the inventors have determined that in accordancewith exemplary embodiments, including a method 300 shown in FIG. 12,that further treating the coating 101 or a portion of the coatingfollowing deposition allows the effect of the inferior properties to beameliorated without sacrificing improved hardness and/orwear-resistance, while maintaining the advantages of using a gaseousoxidizing reagent, although oxidizing reagents can also be used inaccordance with exemplary embodiments as previously described.

Referring to FIG. 12, in one embodiment, the method 300 includestreating (for example, heating and/or modifying the surface of) thelayer 102 of the substrate 100 (step 207) to form a treated layer 806,further described below with reference to FIG. 13. The method 300includes the method 200 shown in FIG. 4 and the treating (step 207). Inone embodiment, the treating (step 207) follows the oxidizing (step205), for example, of the initially-oxidized layer 802. In a furtherembodiment, functionalizing (step 209) follows the treating (step 207).Accordingly, in one embodiment, the oxidized layer, such as anair-oxidized layer 805, is treated (step 207) to form the treated layer806 (for example, a trimethylsilyl treated amorphous carboxysilanelayer) as illustrated in FIG. 13.

Referring to FIGS. 13 and 14, the treated layer 806 can have greaterwear resistance than the functionalized layer 110 formed withdimethylsilane and/or the air-oxidized layer 805. As such, in oneembodiment of the method 300, the treating (step 207) increases wearresistance. For example, in one embodiment, the treated layer 806 hasabout a thirty-four-fold improvement in wear resistance over thefunctionalized layer 110 formed with dimethylsilane. Forming the treatedlayer 806 (for example, an air-oxidized carboxysilane layer) may beperformed by reacting (for example, with —OH (hydroxyl) groups onsilicon (silanols)) to undergo a condensation reaction (for example,with Si—H (silane) groups). In one embodiment, the treating (step 207)includes the following reaction:R₃Si—OH+H—SiR′₃→R₃Si—O—SiR′₃+H₂ (R and R′=organo groups)

By modifying and varying the R′ groups, or by using other moleculescapable of hydroxyl reactivity, surface properties of the treated layer806 (for example, the air-oxidized carboxysilane layer) are adjusted.For example, in one embodiment, the adjustments increase or decreasehardness and wear resistance, inertness, electrochemical impedance,contact angle, and combinations thereof, thereby providing physicalperformance characteristics expanding the applicability and durabilityfor use in the fields of process, analytical, gas, oil and semiconductorindustries. The R-groups can be formed by hydrocarbons, substitutedhydrocarbons, carbonyls, carboxyls, esters, ethers, amines, amides,sulfonic acids, organometalic complexes, and/or epoxides. Although notintending to be bound by theory, it is believed that the moieties ofsilicon hydride can thermally react, via a hydrosilyation mechanism,with unsaturated hydrocarbon groups to covalently bond to the surface ofthe coated substrate. In one embodiment, the coating 101 on all exposedsurface within the reaction chamber includes covalently-bound R-groupswhich include the R-group and carbon, silicon, and hydrogen moieties.

FIG. 14 illustrates diffusion of the treated layer 806 into thesubstrate 100 (for example, stainless steel) according to an exemplaryembodiment. Specifically, FIG. 14 shows the composition of the treatedlayer 806 within the substrate 100 and/or article 103 by Auger ElectronSpectroscopy. In one embodiment, the treatment (step 207) results in asubstantially stable concentration of Si, O, and C throughout thetreated layer 806 until reaching the diffusion layer 108. In thisembodiment, Si, O, and C atomic concentrations are at about 40%, 35%,and 20%, respectively. In one embodiment, the treated layer 806 extendsto about 3500 Angstroms and includes the diffusion region 108 beingabout 400 Angstroms, identifiable based upon a decreased concentrationof C and Si and a spike and then decrease in O. The range of the treatedlayer 806 can be between about 0.1 micrometers and about 3.0micrometers. The diffusion region 108 can be between about 5 nanometersand 500 nanometers. The composition of the treated layer 806 is about1.0:2.25:1.75 (C:Si:O).

In one embodiment, the treating (step 207) includes exposure of thearticle 100, the coating 101, the layer 102, the functionalized layer110, the air-oxidized layer 805, or combinations thereof to anorganosilane reagent. In one embodiment, the organosilane reagent is atrifunctional organosilane that consists of the general formulaRR′R″Si—H, where R,R′,R″ are organofunctional groups. Examples of theorganofunctional groups are alkyl, aryl, halogenated alkyl and aryl,ketones, aldehydes, acyl, alcohol, epoxy, and nitro-organo groups, andorganometallic functionalities. In one embodiment, the organosilane istrimethylsilane.

Heat, exposure times, diluent gases, and pressures are adjusted toaffect the degree of treating (step 207). Control of this degree oftreating (step 207) imparts the desired properties. In one embodiment,the oxidized layer is exposed to the organosilane reagent at atemperature of about 300 to 600° C., for about 1 to 24 hours and at apressure of about 5 to 100 psia, in some cases about 25 psia, about 27psia, about 54 psia, or any suitable ranges therebetween. Inert diluentgases may be used, such as argon or nitrogen, at partial pressures ofabout 1 to 100 psia to assist the reaction.

In one embodiment, the air-oxidized layer 805 (for example, adimethylsilane-based carboxysilane layer formed by air-oxidizing thelayer 102) is treated by exposure to trimethylsilane (for example, at450° C. for 10 hours at 25 psia). In this embodiment, the treated layer806 includes a loss of Si—OH functionality (in comparison to theair-oxidized layer 805, see FIG. 15 at 3411.8 cm⁻¹), an increase incontact angle measurement (for example about 99.1° for deionized waterin comparison to about 50.9° prior to the reaction), a presence ofhydrophobicity, excellent impedance (for example, at low frequency(Z_(lf)) of about 15.4 Mohm (increased from a Z_(lf)=about 7.27 kohmfrom the air-oxidized layer 805, FIGS. 16 and 17), and/or a terminalZ_(R)/Z_(l) ratio of about 0.072 from a Nyquist plot, FIGS. 18 and 19),and combinations thereof.

In the embodiments, it is desirable to provide adequate wear resistanceto prevent surface wear of the components, which includes wear (surfacesin sliding or rolling motion) and friction (resistance to relativemotion of contacting bodies), of the components on which the coating 101and/or the layer 102 is deposited. Wear occurs where two surfaces ormaterials undergo movement, such as sliding or rolling under load. Wearis essentially a process of the removal of material from a solid surfaceand can be caused by abrasion, erosion, adhesion, surface fatigue and/orcorrosion. Examples of applications in which wear occurs are illustratedin FIGS. 20 and 21. FIG. 20 illustrates an application in which twosurfaces 901 and 902 are in contact and are moved relative to each otherin a reciprocating motion. In the exemplary embodiment shown, thesurfaces are on a piston head 903 and a cylinder 904, but the surfacescould be on any moving parts. FIG. 21 illustrates an application iswhich a surface 910 contacted by a moving fluid. In the exemplaryembodiment shown, the surface is the interior of a pipe 911 throughwhich a fluid such as gas and/or liquid flow(s), as indicated by arrows912, but the surface could be on any part which is in contact with fluidmotion.

With proper wear resistance, surface wear is reduced thereby effectivelyextending the operational life of the component. As operationalenvironments are normally complex, it is important that the coating 101and/or the layer 102 be formulated to prevent both the chemical andphysical degradation to the surface of the component. An example of anapplication of a component working in an aggressive environment is adrilling tool used in the oil and gas industry. The tool experienceshigh loads, high speeds and friction and, as a consequence hightemperatures. These factors can lead to surface wear of the components.Other such applications in aggressive or harsh environments in which thecoating 101 and/or the layer 102 may be of benefit, include, but are notlimited to, systems or components with particulate flow and/or slidingwear. Such applications include, but are not limited to, tubing,fittings, valves (rotary, ball, slide, etc.), injectors, piston rings,sliding o-rings, cylinders, regulators, mixing systems, samplingapparatus, analytical systems for use in the oil and gas industry,process and analytical equipment, internal combustions engines,semiconductors, and the like.

While the coating thickness depends on the geometry of the part to becoated and the type of finish required, in an exemplary embodiment madeaccording to the methods disclosed, the coating 101 or the layer 102 hasa thickness of about 100 nm to about 10,000 nm or, more specifically,about 200 nm to about 5,000 nm, or, even more specifically, about 300 nmto about 1500 nm. The wear resistance ranges between about 13×10⁻⁵mm³/Nm and about 0.5×10⁻⁵ mm³/Nm, or more specifically, between about9×10⁻⁵ mm³/Nm and about 1×10⁻⁵ mm³/Nm, or, even more specifically,between about 6.2×10⁻⁵ mm³/Nm and about 1.3×10⁻⁵ mm³/Nm. The coefficientof friction ranges between about 0.58 and about 0.05 or, morespecifically, between about 0.5 and about 0.075, or, even morespecifically, between about 0.38 and about 0.1.

The coatings 101 and/or the layers 102 applied in accordance herewithimprove resistance to the wear caused by stress interactions anddeformation properties of the mating surfaces, such as abrasion,adhesion and fatigue. Abrasive wear (also referred to as scratching,gouging or scoring) occurs when material is removed from one surface byanother harder material, leaving hard particles of debris between thetwo surfaces. Adhesive wear (often called galling or scuffing) occurswhere interfacial adhesive junctions lock together as two surfaces slideacross each other under pressure. As normal pressure is applied, localpressure at the asperities become extremely high, often exceeding theyield stress causing the asperities to deform plastically. Fatigueoccurs when the periodic motion of mechanical machinery cause stressesto the surfaces of the component. These effects are mainly based on theaction of stresses in or below the surfaces, without the need of directphysical contact of the surfaces under consideration. When two surfacesslide across each other, the maximum shear stress lies some distancebelow the surface, causing microcracks which propagate to the surface,which lead to failure of the component.

In addition the coating 101 and/or layer 102 improve the resistance ofthe surface of the component to erosion (from both solid and liquid) andcorrosion. Erosion (from both solid and liquid) occurs when an impingingparticle or stream contacts the surface of the component. In corrosivewear the connecting surfaces react with the environment and reactionproducts are formed on the surface asperities. Attrition of the reactionproducts then occurs as a result of crack formation, and/or abrasion, inthe contact interactions of the materials.

The coating 101 and/or the layer 102 made and applied in accordanceherewith provides increased adhesion of the coating 101 and/or the layer102 to the substrate 100, thereby improving the wear characteristics ofthe coating 102 and/or the layer 102. The coating 101 and/or the layer102 is hard and adheres tenaciously to a bearing surface of thesubstrate 100. This allows the coating 101 and/or the layer 102 to beused in aggressive or harsh environments in which the substrate 100 isexposed is subject to wear and/or erosion. In the exemplary embodimentshown in FIG. 20, either surface 901, 902 may have the coating 101applied thereto. Alternatively, both surfaces 901, 902 may have thecoating applied. In the exemplary embodiment shown in FIG. 21, thesurface 910 may have the coating 101 applied. In addition, an outersurface 913 may have the coating 101 applied to protect the item 911from damage during transportation and the like.

EXAMPLE 1

The first example included introducing dimethylsilane to the substrate100 for 2 hours at 8 psia gas at 450° C. to form the layer 102. In thefirst example, the layer 102 was almost undetectable (i.e., verydifficult to visually discern) on a mirror-polished 316 stainless steelcoupon (slightly yellowed). Measurements showed water contact angle dataprior to the deposition treatment at around 60°. After the depositiontreatment with dimethylsilane, the contact angle increased to around102°. Although the layer 102 was not visible, the data indicated anextremely thin deposition with a significant density of carbosilylmaterial on the layer 102 of the surface 105. The thickness of the layer102 was estimated to be at about 100 Angstroms as availablespectroscopic techniques were not sensitive enough to detect thecoating.

EXAMPLE 2

The second example included introducing dimethylsilane to the substrate100 for 15 hours at 8 psia gas at 450° C. to form the layer 102. In thesecond example, the layer 102 had a visible luminescent rainbow array ofcolors. Measurements showed average deionized water contact angle dataaround 100°, for mirror-finished 316 stainless steel surfaces andpolished silicon wafer surfaces. FT-IR indicated the presence of C—Hbased upon a reading at 2950 cm⁻¹, the presence of Si—C based upon areading at 792 cm⁻¹, and the presence of Si—H moieties based upon areading at 2102 cm⁻¹. The thickness of the layer 102 was determined byspectrometer to be about 800 Angstroms. Further measurements utilizingAuger Electron Spectroscopy were also performed. The measurements showedincreased concentrations of Si and C atoms on the layer 102. Themeasurement further showed the concentration of Si and C atomsdecreasing upon reaching the diffusion region 108 illustrated by theincrease in concentration of Fe, Cr, and Ni atoms. The measurementshowed the concentration of Si and C atoms being asymptotic with zeroupon reaching a point beyond the diffusion region 108. The measurementalso showed that the diffusion region 108 can be identified based uponthe concentration of O atoms being elevated (the result of a surfaceoxide on the surface 105 of the substrate 100 prior to deposition).

EXAMPLE 3

The third example included introducing dimethylsilane to the substrate100 for 15 hours at 8 psia gas at 450° C. to form the layer 102 andsubsequently oxidizing the layer 102 of the substrate 100 with water inan inert gas for 2 hours at about 100 to 200 psia gas at 450° C. to formthe oxidized layer 802. The third example showed undesirable results.For example, FT-IR data failed to reveal the presence of any functionalmoieties (Si—OH or Si—H) for surface modification chemistry. Theoxidized layer 802 had a contact angle on a Si wafer of 86.6°, and apresence of Si—O—Si groups.

EXAMPLE 4

The fourth example included introducing dimethylsilane to the substrate100 for 15 hours at 8 psia gas at 450° C. to form the layer 102 andsubsequently oxidizing the layer 102 of the substrate 100 with anoxidation reagent mixture for 2 hours at about 100 to 200 psia gas at300° C. to form the oxidized layer 805. The oxidation reagent mixtureincluded air and water. The fourth example showed undesirable results.According to FT-IR data, the oxidized layer 805 was over-oxidized, had adecrease of C—H groups (in comparison to Example 3), a decrease of Si—Cgroups (in comparison to Example 3), and an increase of Si—OH/C—OHgroups (in comparison to Example 3).

EXAMPLE 5

The fifth example included introducing dimethylsilane to the substrate100 for 15 hours at 8 psia gas at 450° C. to form the layer 102 andsubsequently oxidizing the layer 102 on the substrate 100 with air for 2hours at about 100 to 200 psia gas at 300° C. to form the oxidized layer805. The fifth example produced an oxidized carbosilane material with asignificant Si—OH stretch observed in the FT-IR data (broad; 3414 cm⁻¹).Contact angle was measured to be 50.9° for deionized water.Electrochemical impedance spectroscopy showed impedance at low frequencyZ_(lf)=about 7.27 kohm. Wear resistance of the material was analyzedwith a Tribometer (CSM Instruments S/N 18-343) applying a 0.5 N forcevia a standard 100 Cr6 ball and circular linear speed of 3.00 cm/sthereby showing a 4.141×10⁻³ wear (mm³/N m). The oxidized layer 805 hadlower friction (in comparison to Example 3), higher wear (in comparisonto Example 3), and a presence of Si—O—Si groups.

EXAMPLE 6

The sixth example included functionalizing the layer 102 formed inExample 2 with ethylene to form the functionalized layer 110. Thefunctionalized layer 110 had a water contact angle of 98.3° advancingand 85.1° receding. As shown in FIG. 10, FT-IR data showed littleoxidation occurred based upon a lack of Si—O—Si groups (based upon astretch at 1027 cm⁻¹) and decreased an amount of Si—H groups (based upona stretch at 2091 cm⁻¹).

EXAMPLE 7

The seventh example including functionalizing the layer 102 formed inExample 2 with ethylene to form the functionalized layer 110. Then, thefunctionalized layer 110 was oxidized by 5 ml deionized water (DI) beingadded to the chamber. The chamber was exposed to several nitrogenflushes and mild vacuum to remove air from the sealed container. Thetemperature in the chamber was held at 450° C. for about 2 hours, thenreturned to room temperature. The oxidation of the functionalized layer110 formed the functionalized then oxidized layer 804. Thefunctionalized then oxidized layer 804 had a water contact angle data of95.6° advancing and 65.9° receding. As shown in FIG. 10, FT-IR showedthat oxidation increased an amount of Si—O—Si groups (based upon astretch at 1027 cm⁻¹) and decreased an amount of Si—H groups (based upona stretch at 2091 cm⁻¹) in comparison to the functionalized layer 110formed in Example 6.

EXAMPLE 8

The eighth example included introducing trimethylsilane to the layer 102(dimethylsilane) for 15 hours at 8 psia gas at 450° C. The eighthexample showed undesirable results, including no visible orspectroscopically measurable coating on the substrate 100, nor was thereany indication of a molecular coating as there was no significant changein water contact angle values.

EXAMPLE 9

The ninth example included treating the oxidized layer 805 formed inExample 5 with trimethylsilane to form the treated layer 806.Specifically, trimethylsilane was added to an evacuated chamberincluding the material at 450° C. and 25 psia and reacted for about 10hours. Resultant FT-IR data showed a loss of Si—OH functionality (seeFIG. 15). Contact angle was measured to be 99.1° for deionized water,suggesting a presence of hydrophobicity. Electrochemical impedancespectroscopy showed impedance at low frequency (Z_(lf)) of 15.4 Mohm.Electrochemical impedance spectroscopy also showed a Bode plot andterminal Z_(R)/Z_(l) ratio of 0.072 from a Nyquist plot (see FIGS.16-19). Wear resistance of the material was analyzed with a Tribometer(CSM Instruments S/N 18-343) applying a 0.5 N force via a standard 100Cr6 ball and circular linear speed of 3.00 cm/s thereby showing a1.225×10⁻⁴ wear (mm³/Nm), a thirty-four-fold increase in comparison tothe non-treated material.

While only certain features and embodiments of the invention have beenshown and described, many modifications and changes may occur to thoseskilled in the art (for example, variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters (for example, temperatures, pressures, etc.), mountingarrangements, use of materials, colors, orientations, etc.) withoutmaterially departing from the novel teachings and advantages of thesubject matter recited in the claims. The order or sequence of anyprocess or method steps may be varied or re-sequenced according toalternative embodiments. It is, therefore, to be understood that theappended claims are intended to cover all such modifications and changesas fall within the true spirit of the invention. Furthermore, in aneffort to provide a concise description of the exemplary embodiments,all features of an actual implementation may not have been described(i.e., those unrelated to the presently contemplated best mode ofcarrying out the invention, or those unrelated to enabling the claimedinvention). It should be appreciated that in the development of any suchactual implementation, as in any engineering or design project, numerousimplementation specific decisions may be made. Such a development effortmight be complex and time consuming, but would nevertheless be a routineundertaking of design, fabrication, and manufacture for those ofordinary skill having the benefit of this disclosure, without undueexperimentation.

What is claimed is:
 1. An article having a wear coating comprising: alayer treated by trimethylsilane applied to a surface of the articlewherein the wear coating is applied by chemical vapor deposition viathermal decomposition of dimethylsilane; wherein constituents of thedecomposed dimethylsilane are oxidized prior to trimethylsilanetreatment.
 2. The article of claim 1, wherein the article is inreciprocating contact with a second article.
 3. The article of claim 2,wherein the article is a piston head or a piston cylinder.
 4. Thearticle of claim 1, wherein the article is a drilling tool.
 5. Thearticle of claim 1, wherein the surface is an interior surface of thearticle.
 6. The article of claim 1, wherein constituents of thedecomposed dimethylsilane are functionalized.
 7. The article of claim 1,wherein the wear coating has a thickness of about 100 nm to about 10,000nm.
 8. The article of claim 1, wherein the wear coating has a wearresistance between about 13×10⁻⁵ mm³/Nm and about 0.5×10⁻⁵ mm³/Nm uponapplication of a 0.5 N force via a standard 100 Cr6 ball and circularlinear speed of 3.00 cm/s.
 9. The article of claim 1, wherein the wearcoating has a coefficient of friction between about 0.58 and about 0.05.10. The article of claim 1, wherein the surface of the article to whichthe wear coating is applied is metal or metallic.
 11. The article ofclaim 1, wherein the wear coating has a thickness in the range of about100 nm to about 10,000 nm, a wear resistance in the range of about13×10⁻⁵ mm³/Nm to about 0.5×10⁻⁵ mm³/Nm upon application of a 0.5 Nforce via a standard 100 Cr6 ball and circular linear speed of 3.00cm/s, and a coefficient of friction between about 0.58 and about 0.05.12. The article of claim 1, wherein the wear coating has a thickness ofabout 200 nm to about 5,000 nm.
 13. The article of claim 1, wherein thewear coating has a thickness of about 300 nm to about 1,500 nm.
 14. Thearticle of claim 1, wherein the constituents of the decomposeddimethylsilane that are oxidized form an oxidized layer.
 15. The articleof claim 14, wherein the oxidized layer extends for 1,600 Angstroms. 16.The article of claim 1, wherein the thermal decomposition of thedimethylsilane is at a temperature between 400° C. and 500° C.
 17. Thearticle of claim 1, wherein the surface of the article to which the wearcoating is applied is ceramic.
 18. The article of claim 1, wherein thesurface of the article to which the wear coating is applied is glass.19. An article, comprising a dimethylsilane-based layer on the article,an oxidization of the dimethylsilane-based layer on thedimethylsilane-based layer, and a trimethylsilane-based treatment on theoxidation.